Helical Submerged Arc Welding (HSAW) Steel Pipe Market: Market Growth Factors, Applications, Regional Analysis, Key Players And Forecasts By 2025

Submerged arc welding (SAW) is a common arc welding process. The first patent on the submerged-arc welding (SAW) process was taken out in 1935 and covered an electric arc beneath a bed of granulated flux. Originally developed and patented by Jones, Kennedy and Rothermund, the process requires a continuously fed consumable solid or tubular (metal cored) electrode. The molten weld and the arc zone are protected from atmospheric contamination by being "submerged" under a blanket of granular fusible flux consisting of lime, silica, manganese oxide, calcium fluoride, and other compounds. When molten, the flux becomes conductive, and provides a current path between the electrode and the work. This thick layer of flux completely covers the molten metal thus preventing spatter and sparks as well as suppressing the intense ultraviolet radiation and fumes that are a part of the shielded metal arc welding (SMAW) process.

What is submerged arc welding used for?

Submerged Arc Welding. Submerged arc welding is commonly used in industries where thick steel sheets are involved or where long welds are required. The process consists in creating a welded joint between steel components using an electric arc submerged beneath a layer of powdered flux. Granular flux used in welding is a type of granular insulative material that is made up of numerous small particles. In Submerged Arc Welding (SAW), the granular flux provides a blanket over the weld, which protects against sparks and spatter.

Global Helical Submerged Arc Welding (HSAW) Steel Pipe market competition by top manufacturers/players, with Helical Submerged Arc Welding (HSAW) Steel Pipe sales volume, Price (USD/MT), revenue (Million USD) and market share for each manufacturer/player; the top players including

PSL

Jindal Saw

Welspun Corp

Man Industries

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Features of Helical Submerged Arc Welding (HSAW) Steel Pipe Market:

Welding head
It feeds flux and filler metal to the welding joint. Electrode (filler metal) gets energized here.

Flux hopper
It stores the flux and controls the rate of flux deposition on the welding joint.

Flux
The granulated flux shields and thus protects molten weld from atmospheric contamination. The flux cleans weld metal and can also modify its chemical composition. The flux is granulated to a definite size. It may be of fused, bonded or mechanically mixed type. The flux may consist of fluorides of calcium and oxides of calcium, magnesium, silicon, aluminium and manganese. Alloying elements may be added as per requirements. Substances evolving large amount of gases during welding are never mixed with the flux. Flux with fine and coarse particle sizes are recommended for welding heavier and smaller thickness respectively.

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Electrode
SAW filler material usually is a standard wire as well as other special forms. This wire normally has a thickness of 1.6 mm to 6 mm (1/16 in. to 1/4 in.). In certain circumstances, twisted wire can be used to give the arc an oscillating movement. This helps fuse the toe of the weld to the base metal. The electrode composition depends upon the material being welded. Alloying elements may be added in the electrodes. Electrodes are available to weld mild steels, high carbon steels, low and special alloy steels, stainless steel and some of the nonferrous of copper and nickel. Electrodes are generally copper coated to prevent rusting and to increase their electrical conductivity. Electrodes are available in straight lengths and coils.

Advantages Of Helical Submerged Arc Welding (HSAW) Steel Pipe Market:

High deposition rates (over 45 kg/h (100 lb/h) have been reported).
High operating factors in mechanized applications.
Deep weld penetration.
Sound welds are readily made (with good process design and control).
High speed welding of thin sheet steels up to 5 m/min (16 ft/min) is possible.
Minimal welding fume or arc light is emitted.
Practically no edge preparation is necessary depending on joint configuration and required penetration.
The process is suitable for both indoor and outdoor works.
Welds produced are sound, uniform, ductile, corrosion resistant and have good impact value.
Single pass welds can be made in thick plates with normal equipment.
The arc is always covered under a blanket of flux, thus there is no chance of spatter of weld.
50% to 90% of the flux is recoverable, recycled and reused.
Limitations of Helical Submerged Arc Welding (HSAW) Steel Pipe Market:

Limited to ferrous (steel or stainless steels) and some nickel-based alloys.
Normally limited to the 1F, 1G, and 2F positions.
Normally limited to long straight seams or rotated pipes or vessels.
Requires relatively troublesome flux handling systems.
Flux and slag residue can present a health and safety concern.
Requires inter-pass and post weld slag removal.
Requires backing strips for proper root penetration.
Limited to high thickness materials.
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